Washable protective pad

ABSTRACT

A thin, lightweight, flexible, washable protective pad is incorporated into a pocket of a washable garment, such as at the hip. This pad comprises an air-impermeable envelope extending substantially throughout the pocket, a compressible insert having a configuration that extends substantially throughout the envelope and a junction arrangement between the insert and the envelope. The arrangement is such that the extent of the configuration of the insert is maintained substantially throughout the envelope. The arrangement remains intact when the pad is repeatedly bent, twisted or otherwise deformed during washing or wearing, maintaining the pad&#39;s protective function. In other configurations, the insert may be captured by a seal that joins the sheet or sheets that form the walls of the envelope. The disposition of the insert with respect to the envelope may thereby be maintained.

[0001] The present application is a continuation-in-pail of U.S.application Ser. No. 10/273,985, filed on Oct. 18, 2002, entitled“Washable, Protective Hip Pad Construction,” which is incorporatedherein by reference.

TECHNICAL FIELD

[0002] The present invention relates to protective anatomical pads thatmay be worn to guard against injuries from impact or pressure.

BACKGROUND

[0003] What might be a minor injury to a young person might constitute aserious trauma to an elderly or infirm person. Injuries to the hip are arelatively common and important case in point. Protective pads have beenprovided for incorporation in patch pockets of underbriefs for elderlyand/or infirm men and women. These patch pockets and the protective padsthey contain cover the hip bones and overlap adjacent anterior andposterior regions, particularly of the buttocks. Such patch pocketsposition the protective pads to protect against physical shock due toinadvertent falling or other physical contact. For this purpose, oneexample of a protective pad of the prior art is a thin assemblage thatcomprises a hermetically sealed plastic envelope and an open cell foaminsert contained freely therein. In a particular prior art example, theenvelope is in the form of a thin film, composed for example ofpolyurethane backed by nylon fabric, and the insert is in the form of athin solid foam stratum having an internal phase composed of open cellsof air, and an external phase composed of elastomeric polyurethane.

[0004] The pad should be sufficiently flexible for comfort. On impact atany point or region of the pad, air inside the insert and in the spacebetween the insert and the envelope distributes the force of the impactand reduces its intensity at the impact point. A problem with such padshas been a tendency of the insert to crumple and/or roll up during thetumbling that occurs when the underbrief and pad are machine washed.Specifically, when the insert is not substantially fully extended withinthe envelope but is crumpled into a mass, the product may becomeunwearable.

SUMMARY OF THE INVENTION

[0005] In a first embodiment of the invention there is provided awashable protective pad. The pad is constructed from overlaid sheetsjoined by a seal to form an air impermeable envelope. A compressibleinsert is disposed at least partially within the chamber formed by theenvelope. Part of the seal joining the overlaid sheets holds the insert,reducing movement of the insert with respect to the envelope. Thisarrangement permits the pad to maintain its shape and protectiveattributes after repeated washings. In a specific embodiment of theinvention, the surface of the insert is also stuck to the inner surfaceof the envelope through adhesive or thermoplastic adhesion or othermeans.

[0006] In another embodiment of the invention, a compressible insert isdisposed within the chamber formed by overlaid sheets. The seal betweenthe overlaid sheets of the envelope does not capture the insert. Part ofthe surface of the insert is stuck to the inner surface of the envelopethrough adhesive or thermoplastic adhesion or by other means. In thisembodiment of the invention, movement of the insert with respect to theenvelope is reduced by adhesion of the insert to the envelope wall,allowing the pad to maintain its shape and protective attributes aftermultiple washings.

[0007] In a further embodiment of the invention, a single sheet isfolded upon itself with the edges of the sheet sealed to form an airimpermeable envelope. A compressible insert is disposed at leastpartially within the chamber formed by the envelope. The insert may becaptured by the seal that joins the edges of the sheet and/or thesurface of the insert may be stuck to the walls of the chamber.

[0008] In another embodiment of the invention, a method is provided toprotect an individual from a force. The force may be an impact from afall or pressure from a mattress for a bed-ridden individual or anyother force. A protective pad according to any of the above embodimentsis incorporated into a garment worn by the individual. The pad may beincorporated by insertion into a pocket in the garment or by attachingthe pad to the garment or by other means. The pad is disposed betweenthe portion of the individual's anatomy to be protected and the sitewhere the force may impact the individual.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The foregoing features of the invention will be more readilyunderstood by reference to the following detailed description, takenwith reference to the accompanying drawings, in which:

[0010]FIG. 1 is a perspective view of a hip pad according to anembodiment of the present invention;

[0011]FIG. 2 is a view of a washable underbrief that incorporates a pairof washable hip pads in accordance with an embodiment of the presentinvention;

[0012]FIG. 3 is an exaggerated cross-sectional view of the hip pad ofFIG. 1, taken along the lines 3-3 of FIG. 1;

[0013]FIG. 4 is an exaggerated cross-sectional view, analogous to thatof FIG. 3, illustrating details of another embodiment of the presentinvention;

[0014]FIG. 5 is an exaggerated cross-sectional view, analogous to thatof FIG. 3, illustrating details of a further embodiment of the presentinvention;

[0015] FIGS. 6A-6C illustrate several configurations of the insertcaptured by part of the seal; and

[0016]FIG. 7 is an exaggerated cross-sectional view, analogous to thatof FIG. 3, illustrating an insert partially captured by a seal thatjoins the sheets.

DETAILED DESCRIPTION OF SPECIFIC EMBODIMENTS

[0017] Note that, as used in this description and the accompanyingclaims unless the context otherwise requires, the word “part” will takeits normal meaning as meaning at least a portion but less than thewhole.

[0018] In embodiments of the present invention, a washable pad protectspart of a human's anatomy, such as a hip, from a force. For example, theforce may be an impact from striking a surface during an accidentalfall. Another exemplary force is pressure from a mattress or from awheelchair seat for an infirm individual, which may lead to bedsores.The pad is constructed to allow multiple washings while maintaining itsshape and its protective features.

[0019] For example, in an embodiment of the present invention, asillustrated in FIGS. 1 to 2, an underbrief 20 has a pair of opposedpatch pockets 22 and 24. Each pocket extends over a hip and overlapsregions of the body that are anterior and posterior with respect to thehip. Confined within and extending throughout the pockets are washable,protective pads 26 and 28. While each pad illustrated is round, pads inother shapes, such as oval or rectangular may be used. Generally, thearea and thickness of the pad may be less than 90 square inches and lessthan 1 inch, respectively, so that the pad may be worn comfortably. Inother embodiments of the invention, the pad may be any size, shape andthickness necessary to protect an area of the body.

[0020] A washable protective pad may be made in a variety ofconstructions according to embodiments of the invention. As shown inFIG. 3, a protective pad 26 generally comprises an external envelope 30and an insert 32. The envelope is impermeable to air and may be made ofany suitable material, such as plastic or a coated nylon fabric. Theenvelope may be advantageously formed from separate sheets that aresealed together, at least at their edges, or may be made from a singlesheet that is folded upon itself and sealed at its edges. The seal thatjoins the sheets may be adhesive or thermoplastic molding or a weld,such as a radiofrequency induced weld, or another sealing techniquesuitable for the materials forming the envelope. Preferably, theexternal envelope and the insert are substantially coextensive. Theinner surface of the walls of the envelope defines an inner area, whichmay be a laminar region 38 as shown in FIG. 3, or a chamber of anyarbitrary shape. Insert 32 may be an open cell, solid foam having alaminar configuration that extends substantially throughout innerlaminar region 38 in contiguity with the opposed inner faces of walls 34and 36. In other embodiments of the invention a wide range ofcompressible materials may be used for the insert. The insert preferablyis also resilient, so that the pad may sustain multiple impacts andmaintain its protective function.

[0021] In embodiments of the present invention, the insert may beattached to the envelope at one or more points so that the dispositionof the insert with respect to the envelope may be substantiallymaintained when the pad is washed. Thus, the pad will retain itswearability and protective function throughout its lifetime. As shown inFIG. 3, the edges of the envelope may be sealed together as at 40 and 42throughout their peripheries, providing an outwardly extendingperipheral flange shown at 44 and 46. In the embodiment of the inventionshown in FIG. 3, no part of the flange or seal between the faces of theenvelope holds the insert—movement between the insert and the envelopeis reduced by sticking the insert to the inner walls of the envelope

[0022] FIGS. 3-5 shows embodiments of the invention in which the surfaceof the insert is bonded to the inner wall of the envelope. The bondsbetween the surface of the insert and the inner surface of the envelopewalls may be made by any convenient technique, such as by gluing or bythermoplastic melting or by other techniques as are known in the art. Asshown in FIGS. 3-5, the opposed faces of the insert 32 are generallycontiguous with, i.e. in free contact with or slightly spaced from, theinner faces of walls 34 and 36 at cleavage regions 35 and 37. Insert 32is bonded to the inner face of wall 36 by four spot junctions 48, 50, 52and 54, which are located equidistantly around the circumference of theenvelope, as shown in FIG. 1.

[0023] Another embodiment of the invention is shown in FIG. 4. Here, theenvelope walls are shown at 56 and 58 as being bonded around theirperiphery, as at 60 and 62. Within the envelope is an insert 64. Oneface of insert 64 is bonded to the inner face of wall 56 by four spotjunctions, two of which are shown at 66 and 68. The other face of insert64 is bonded to the inner face of wall 58 by four spot junctions, two ofwhich are shown at 70 and 72.

[0024] A further embodiment of the invention is shown in FIG. 5. Here,the envelope walls are shown at 76 and 78 as being sealed around theirperiphery, as at 80 and 82. Within the envelope is an insert 84. Oneface of insert 84 is connected to the inner face of wall 78 by ajunction in the form of a bonding stratum 86 between the contiguousfaces of insert 84 and wall 78. The other face of insert 84 is free.

[0025] In other embodiments of the invention, the seal, which joins thesheets or the portions of a single sheet that comprise the airimpermeable envelope, captures and holds the insert. The seal may bemade preferably by radio-frequency induced welding or by other joiningtechniques as are known in the art. This technique for holding theinsert may be used alone or in combination with sticking the insert tothe wall of the chamber formed by the envelope, as illustrated by FIGS.3-5. The insert may be held by any part of the seal or by the entireseal. The seal may be contiguous, in a manner similar to the flangeshown in FIGS. 1 and 3 or may be any combination of spot or strip seals.When the seal between the faces of the envelope captures the insert,movement between the insert and the envelope is reduced, maintaining thedisposition between the envelope and the insert, when the pad is worn orlaundered.

[0026] By way of example, insert 132 may be circular in shape with tabs170 extending from the body of the insert, as shown in the top-downpartial view in FIG. 6A. These tabs may be captured in the seal 140, 142(shown as the area between dotted lines) as the seal is joined.Alternatively, the insert may be circular in shape and the diameter ofthe insert may be such that the insert edge 150 is captured by the sealaround the periphery of the pad, as shown in FIG. 6B The edge of theinsert 150 may be beveled so that the portion of the insert captured bythe seal is thin, facilitating an air-tight seal. As shown in FIG. 6C,the insert may be circular in shape with a diameter such that the sealaround the periphery does not capture the insert, but spot seals 180adjacent to the peripheral seal do capture the insert. Otherarrangements of seals with various size, shapes and placements may bemade and all such arrangements are intended to be within the scope ofthe invention as described in the appended claims. FIG. 7 shows across-sectional view of the pad for the configuration of FIG. 6B. Thepad may have a thin space 138 between insert 132 and envelope wall 130.

[0027] The following non-limiting examples further illustrateembodiments of the present invention.

EXAMPLE I

[0028] In the example of the assemblage illustrated in FIG. 3, detailsof the various components are as follows. Each of the envelope walls iscomposed of a laminate having an outer fabric stratum and an innerthermoplastic stratum. The insert is composed of an open cell solid foamhaving an internal air phase and an external thermoplastic phase.Preferably, the inner thermoplastic stratum of each wall and theexternal phase of the insert are composed of essentially the samethermoplastic, for example, polyurethane. Preferably, the fabric stratumis composed of a textile produced from a high melting point plastic(450° F.) sold by DuPont™ under the trade designation, “NYLON”. Thefabric typically is in the range of from 50 to 90 denier, and preferablyis approximately 70 denier. The thickness of the laminate of each wallranges from 1 to 6 mils and preferably is approximately 3 mils.

EXAMPLE II

[0029] In furtherance of EXAMPLE I, the junctions are formed by weldingtogether the thermoplastic faces of the walls throughout theirperimeters, and spot welding the walls to the insert at a temperatureabove the softening point of polyurethane and under a pressure necessaryto achieve coalescence and integration of the polyurethane surfaces.Typically, the diameter of each of the spot welds range from ½ to 1-½inch, and preferably no greater than 1 inch. In essence the diameters ofthe junctions are limited to preserve lateral flexibility and free flowof air between the open cells of the insert and the adjacent cleavageregions.

EXAMPLE III

[0030] In the embodiment of FIG. 4, the materials of the walls and theinsert are respectively identical to their counterparts in FIG. 3.However, here there area two sets of four equidistantly spacedjunctions. Two of the junctions of one of the sets are shown at 66 and68 between insert 64 and wall 56. Two of the junctions of the other ofthe sets are shown at 70 and 72 between insert 64 and wall 58.

EXAMPLE IV

[0031] In the embodiment of FIG. 5, the materials of the walls and theinsert are respectively identical to their counterparts in FIG. 3. Here,chemical bonding is achieved with a flexible polymeric adhesive,preferably a flexible polyurethane adhesive. As shown, one of the facesof insert 84 is bonded by flexible polyurethane adhesive stratum 86 tothe inner face of wall 78. The other of the faces of insert 84 is freefor the purpose of maintaining flexibility. Also, the two walls 76 and78 are bonded by flexible polyurethane adhesive throughout theirperipheries as shown at 80 and 82.

APPLICATION

[0032] In embodiments of the invention, a protective pad as described inany of the preceding embodiments, may be incorporated into any garmentworn by an individual. The pad may be inserted into a pocket or may beattached to the garment, such as by fasteners made of Velcro™ or byother suitable fasteners. For example, a suitably-sized pad may beincorporated into pajamas for a bed-ridden subject. The pad is attachedto the pajamas so that as the subject lies in bed the pad serves tocushion the subject's skin from pressure due to gravity acting on thebed's mattress. Bedsores and other skin irritations may be avoided. Asanother example, the pad may be inserted into a pocket in underbriefs,as shown in FIG. 2, and may protect an individual from hip injury shouldan accidental fall occur.

What is claimed is:
 1. A washable protective pad for incorporation intoa garment, the pad comprising: a. an air-impermeable envelope, theenvelope comprising overlaid sheets joined by a seal, the sheetsdefining a chamber; and b. a compressible insert at least partlydisposed within the chamber such that part of the seal holds the insert.2. A pad according to claim 1, wherein part of the insert is stuck to aninterior surface of the envelope.
 3. A pad according to claim 1, whereinpart of the insert is stuck to the envelope by an adhesive.
 4. A padaccording to claim 1, wherein part of the insert is stuck to theenvelope by a weld.
 5. A pad according to claim 4, wherein the weld is aradiofrequency induced weld.
 6. A pad according to claim 1, wherein theenvelope includes a coated fabric.
 7. A pad according to claim 1,wherein the envelope includes a plastic.
 8. A washable protective padfor incorporation into a garment, the pad comprising: a. anair-impermeable envelope, the envelope comprising overlaid sheets joinedby a seal, the sheets defining a chamber; and b. a compressible insertdisposed within the chamber, a part of the insert stuck to the envelopeand no part of the seal holding the insert.
 9. A pad according to claim8, wherein part of the insert is stuck to the envelope by an adhesive.10. A pad according to claim 8, wherein part of the insert is stuck tothe envelope by a weld.
 11. A pad according to claim 10, wherein theweld is a radiofrequency induced weld.
 12. A pad according to claim 8,wherein the envelope includes a coated fabric.
 13. A pad according toclaim 8, wherein the envelope includes a plastic.
 14. A washableprotective pad for incorporation into a garment, the pad comprising: a.an air-impermeable envelope, the envelope comprising a sheet folded uponitself, the edges of the sheet joined by a seal, the sheet defining achamber; and b. a compressible insert at least partially disposed withinthe chamber.
 15. A pad according to claim 14 wherein at least part ofthe insert is stuck to a wall of the chamber.
 16. A method forprotecting a portion of a body from a force, the method comprising: a.providing a protective pad, the pad comprising, i an air-impermeableenvelope, the envelope comprising overlaid sheets joined by a seal, thesheets defining a chamber, and ii a compressible insert at least partlydisposed within the chamber such that part of the seal holds the insert;and b. incorporating the pad into a garment, the pad incorporated suchthat the pad is disposed between the portion of the body and the forcewhen the garment is worn.
 17. A method according to claim 17, whereinthe portion of the body is a bone.
 18. A method according to claim 17,wherein the portion of the body is a patch of skin.
 19. A method forprotecting a portion of a body from a force, the method comprising: a.providing a protective pad, the pad comprising i an air-impermeableenvelope, the envelope comprising overlaid sheets joined by a seal, thesheets defining a chamber, and ii a compressible insert disposed withinthe chamber, a part of the insert stuck to the envelope and no part ofthe seal holding the insert; and b. incorporating the pad into agarment, the pad incorporated such that the pad is disposed between theportion of the body and the force when the garment is worn.
 20. A methodaccording to claim 19, wherein the portion of the body is a bone.
 21. Amethod according to claim 19, wherein the portion of the body is a patchof skin.